Cover assembly for rail vehicle with built-in generator and axle assembly with this cover

Abstract

Cover assembly (130) installed in an axle assembly (100) comprising an axle (102) rotating by means of a force transmitted from a power source, a housing (140) surrounding an end section of the axle (102), and a bearing (120) arranged between the end section of the axle (102) and the housing (140) to rotatably mount the axle (102) on the housing (140), the cover assembly (130) comprising: a bearing cover (150) with a space therein; a generator (180) with a rotor (182) functionally connected to and rotating with the axle (102), and a stator (184) surrounding the rotor (182) in a radial direction while maintaining a predetermined distance from the rotor (182) in the radial direction;a printed circuit board (186) electrically connected to the generator (180), providing an input to the stator (184) and receiving an output from the rotor (182); at least one sensor mounted on the printed circuit board (186) that detects at least one physical quantity of the axle assembly (100); and a wireless antenna (162) mounted on the bearing cover (150) capable of wirelessly transmitting data corresponding to at least one physical quantity detected by the at least one sensor, wherein the generator (180), the printed circuit board (186) and at least one sensor are arranged in a space formed by a bearing cover (150), wherein an encoder (183) rotating with the rotor (182) is mounted on the rotor (182) and an encoder sensor (185) detecting the rotation of the encoder (183) is mounted on the stator (184).

Description

Technical area

[0001] The present invention relates to a cover assembly for a rail vehicle with a built-in generator and an axle assembly comprising this, and in particular to a cover assembly for a rail vehicle with an on-board generator which supplies current generated by the use of the rotation of an axle to at least one sensor which detects a physical quantity of the axle assembly in order to ensure sufficient data for a frequency analysis, and to an axle assembly comprising this. State of the art

[0002] The components currently used in a rail vehicle are regularly inspected and repaired or replaced if an anomaly is detected during the inspection. However, since a railway system is a mass transit system, there is a high probability that an accident on the railway system will escalate into a major incident. To prevent accidents on rail vehicles, the axle assembly becomes a crucial component for monitoring.

[0003] The faultiness of a diagnostic object can be confirmed by heat, sound, vibration, etc. With a diagnostic method using heat or sound, a user can easily detect a defect in the diagnostic object, although the user may only detect the defect when it is already quite advanced. Since a diagnostic method using vibration can predict the faultiness of the diagnostic object most quickly, it is the most commonly used method in related technology.

[0004] However, since the data sampling time is very short and the data must be collected in order to apply the diagnostic procedure using vibration, the power consumption for data sampling is very high.

[0005] In general, a rail vehicle consists of several interconnected vehicles, and their operation is controlled by a locomotive. A variety of axle assemblies are mounted on each of these vehicles. If a sensor for sensing physical parameters from the axle assemblies is powered and received via a wired connection, the wiring harness can be complex and prone to failure. Therefore, in recent years, a method has been implemented where the sensor and a server transmit and receive data wirelessly. In this wireless communication setup, data acquisition, signal conversion, and wireless communication are accomplished by integrating a battery into the axle assembly and utilizing its power.As mentioned earlier, the power consumption for data sampling is very high in order to apply the vibration-based diagnostic procedure, so a high-capacity battery would be ideal. However, since the installation space of the axle assembly is limited, a battery with sufficient capacity cannot be used. Consequently, monitoring is only possible once per hour, and it is difficult to collect enough data for a fault diagnosis.

[0006] The information disclosed in this background section is provided solely for a better understanding of the background of the invention and may therefore contain information that is not part of the prior art and is already known to a person skilled in the art in this country. Revelation Technical Problem

[0007] One embodiment of the present invention was made in an effort to provide a cover assembly for a rail vehicle with a built-in generator, which forms a generator capable of generating electricity by using rotation of an axis integrally on an axle assembly to provide energy for data acquisition, signal conversion and wireless communication.

[0008] Another embodiment of the present invention was undertaken in an effort to provide an axle assembly including the cover assembly.

[0009] Another embodiment of the present invention was developed in an effort to provide a cover assembly and an axle assembly that can be easily mounted on the rail vehicle.

[0010] Another embodiment of the present invention was developed in an effort to provide a cover assembly and an axle assembly that facilitate the replacement of defective parts. Technical solution

[0011] One embodiment of the present invention provides a cover assembly that can be installed in an axle assembly comprising an axle rotating using energy transferred from a power source, a housing surrounding an end section of the axle, and a bearing arranged between the end section of the axle and the housing to hold the axle rotatably on the housing.

[0012] The cover assembly may comprise: a bearing cover with a space therein; a generator with a rotor that is functionally connected to the shaft and rotates together with the shaft, and a stator that surrounds the rotor in a radial direction while maintaining a predetermined distance from the rotor in the radial direction; a printed circuit board (PCB) that is electrically connected to the generator, provides an input to the stator and receives an output from the rotor; at least one sensor mounted on the PCB that detects at least one physical quantity of the shaft assembly;and a wireless antenna mounted on the bearing cover and capable of wirelessly transmitting data corresponding to at least one physical quantity detected by the at least one sensor, wherein the generator, the circuit board and the at least one sensor may be arranged in a space formed by a bearing cover.

[0013] The at least one sensor can include an accelerometer that measures the acceleration of the axle assembly and a temperature sensor that measures the temperature of the axle assembly.

[0014] The cover assembly may further include: a power control system mounted on the circuit board that controls the input power applied to the stator and the output power of the rotor; a battery mounted on the circuit board that receives the output power of the rotor and is charged by the power control system; and a wireless communication module mounted on the circuit board that enables data exchange via wireless communication.

[0015] In some aspects, an encoder that rotates along with the rotor can be mounted on the rotor, and an encoder sensor that detects the rotation of the encoder can be mounted on the stator.

[0016] In some aspects, the cover assembly may further include: a bottom cover fitted to one side of the bearing cover; and a bottom rotor connected to one end of the axle, rotating with the axle and extending into the bottom cover by penetrating the bearing cover.

[0017] The rotor and stator can be configured to generate a power output of 10 W or more.

[0018] The at least one sensor can be configured to detect at least one physical quantity of the axis assembly with a sampling rate of 10 kHz or more.

[0019] In some aspects, the cover assembly may also include a holder that is mounted on the stator and electrically connects the circuit board to the generator, and the circuit board can be mounted on the holder.

[0020] The holder can comprise a first and a second holder that are detachably connected to each other, and the circuit board can be positioned between the first and the second holder and attached to the holder by connecting the first and the second holder.

[0021] The first holder can have a first and a second projection that are spaced apart radially and each project axially to one side; the circuit board can be arranged between the first and the second projection; and the second holder can be connected to the first and the second projection.

[0022] The circuit board can be attached to the holder in a removable manner.

[0023] The cover assembly may also contain a protective layer that is attached to the circuit board.

[0024] In some aspects, the circuit board can be divided into two or more functional modules and detachably attached to the holder.

[0025] In some aspects, the holder may also include at least two spokes connecting the first and second projections, and the circuit board may be divided into two or more functional modules and detachably attached to a space formed by the first and second projections and the spokes.

[0026] The cover assembly may further include a protective layer applied to the printed circuit board, and a filler dam may be arranged between the protective layer and a circumference and spoke of the second holder.

[0027] Another embodiment of the present invention provides an axle assembly that may include a cover assembly according to an embodiment of the present invention and a holder attached to a stator and electrically connecting a printed circuit board to the generator. The printed circuit board may be attached to the holder. The axle assembly may further include: an extension section functionally connected to an end section of an axle and extending in an axial direction; a bearing cover coupled to the holder and in which the generator and the printed circuit board are arranged; an axle housing attached to an inner circumferential surface of an end section of a housing; and a connecting adapter for attaching the holder to the axle housing, wherein the printed circuit board may be attached to the holder, and wherein the extension section and a rotor of the generator may be wedge-coupled.

[0028] One end of the extension section can penetrate a bearing cover without impairing the rotation of the bearing cover.

[0029] In some cases, the axle assembly may also include a speed plate mounted at one end of the extension section and a speed sensor housing mounted at one end of the axle housing.

[0030] In some cases, the axle assembly may also include a bottom rotor attached to one end of the extension section, as well as a bottom cover attached to one end of the axle housing.

[0031] The axle assembly may further include: a gearbox that changes the rotational speed of a power source via a plurality of gears and transmits the power, whose rotational speed is changed, to the axle; a gearbox sensor module configured to detect accelerations, rotational speeds and / or temperatures of the plurality of gears; and a wired connector attached to the bearing cover and connected to the circuit board to supply power.

[0032] A measured value from the transmission sensor module can be transmitted wirelessly via the wireless antenna or via the wired connector to the circuit board. Beneficial effects

[0033] According to exemplary embodiments of the present invention, a generator capable of producing electricity by utilizing the rotation of an axis is integrally formed on an axis assembly to supply energy for data acquisition, signal conversion, and wireless communication. In this way, sufficient data for frequency analysis can be secured and an anomaly of the axis assembly can be diagnosed in real time.

[0034] Furthermore, a wireless communication arrangement is used, which simplifies cabling.

[0035] Furthermore, the data acquired via wireless communication between the axle assemblies is transmitted sequentially to a server in order to reduce the generator's capacity.

[0036] A printed circuit board is connected to a cover assembly by a holder to protect the circuit board from external influences.

[0037] Because the circuit board is divided into numerous functional modules and connected to the cover assembly, only a faulty functional module can be detached from the cover assembly and replaced. Therefore, the part can be easily replaced, reducing maintenance costs.

[0038] Furthermore, an effect that can be achieved or predicted by the embodiment of the present invention is disclosed directly or implicitly in the detailed description of the embodiment of the present invention. That is to say, various effects that are predicted according to the embodiment of the present invention are disclosed in the subsequent detailed description. List of characters

[0039] Exemplary embodiments of the present invention are better understood by reference to the following description in conjunction with the accompanying drawings, in which similar reference numerals refer to identical or functionally similar elements. Fig. Figure 1 is a schematic representation of a rail vehicle according to an embodiment of the present invention. Fig. Figure 2 is a schematic cross-sectional view showing an axle assembly according to an embodiment of the present invention. Fig. Figure 3 is a schematic view showing some components of the axle assembly according to an embodiment of the present invention. Fig. Figure 4 is a schematic view showing some components of the axle assembly according to another embodiment of the present invention. Fig. Figure 5 is a schematic cross-sectional view showing a configuration of a cover assembly according to an embodiment of the present invention. Fig. Figure 6 is a schematic top view of a cover assembly according to an embodiment of the present invention. Fig. Figure 7 is a schematic top view of a cover assembly according to another embodiment of the present invention. Fig. Figure 8 shows part of a cross-sectional view along line AA of Fig. 7. Fig. Figure 9 is a schematic top view of a cover assembly according to a further embodiment of the present invention. Fig. Figure 10 shows part of a cross-sectional view along line BB of Fig. 9. Fig. Figure 11 is a cross-sectional view showing some components of an axle assembly according to an embodiment of the present invention. Fig. Figure 12 is a cross-sectional view showing some components of an axle assembly according to another embodiment of the present invention.

[0040] The drawings referred to are not to scale, but rather represent a simplified expression of various preferred features that illustrate a fundamental principle of the present disclosure. For example, certain design features of the present disclosure, including a specific dimension, direction, position, and shape, are partly determined depending on a specific intended application and operating environment. Examples of implementation

[0041] The terms used herein serve only to describe specific embodiments and are not intended to limit the present disclosure. Singular forms used herein also include plural forms unless expressly stated in a particular context. When the terms "include" and / or "comprehensive" are used in this description, it is clear that these terms specify the presence of the mentioned features, numbers, steps, operations, constituents, and / or components, but do not exclude the presence or addition of at least one other feature, number, step, operation, constituent, component, and / or group thereof. The terms "and / or" used herein include any combination of elements that are related and listed together.

[0042] The terminology used here, or any other similar terminology such as "vehicle" or "vehicle", also includes cars, including Sport Utility Vehicles (SUVs), buses, trucks and various commercial vehicles, in addition to a rail vehicle.

[0043] Furthermore, it is desirable that one or more of the following procedures, or aspects thereof, be performed by at least one control unit (e.g., an electronic control unit (ECU), controller, or control server. The terms "control unit," "controller," or "control server" may refer to a hardware device comprising memory and a processor. The memory is configured to store program instructions, and the processor is specifically programmed to execute the program instructions to perform one or more of the processes described in more detail below. The control unit, controller, or control server may control units, modules, parts, devices, or the like. Additionally, the following procedures may be performed by a device that incorporates the control unit or controller together with one or more other components known to those skilled in the art.

[0044] Furthermore, the control unit, controller, or control server according to the present disclosure can be implemented as a non-transitory, computer-readable recording medium containing executable program instructions that are executed by the processor. Examples of computer-readable recording media include, but are not limited to, ROM, RAM, Compact Disk (CD) ROM, magnetic tapes, floppy disks, flash drives, smart cards, and optical data storage devices. The computer-readable recording media can also be distributed over a computer network, and the program instructions can be stored and executed by a distribution scheme such as a telematics server or a Controller Area Network (CAN).

[0045] Fig. Figure 1 is a schematic representation of a rail vehicle according to an embodiment of the present invention.

[0046] As in Fig. As shown in Figure 1, a rail vehicle 1 comprises a plurality of interconnected vehicles. The vehicle is configured to carry a passenger or cargo, and a plurality of bogies 10 are installed on a lower part of the vehicle to enable it to travel on a rail. One of the multiple vehicles may contain an engine room in which a control server 200 may be located.

[0047] The bogie 10 generally has two or three axle assemblies 100 and supports a vehicle body. The bogie 10 comprises a bogie frame, the axle assembly 100 mounted on the bogie frame, a buffer device, a brake device, a traction motor, etc.

[0048] Since bogie 10 is well known to the expert, a more detailed description is omitted.

[0049] The control server 200 controls the operation of the rail vehicle 1 and monitors the components contained within the rail vehicle 1. For example, the control server 200 can be configured to receive a signal corresponding to a physical quantity of the axle assembly 100 from at least one sensor contained in the axle assembly 100 and to diagnose the condition of the axle assembly 100 based on the received signal. Furthermore, the control server 200 can be configured to receive a signal corresponding to a physical quantity of a gearbox 110 from at least one sensor installed in the gearbox 110 (see Fig. 2) and, based on the received signal, diagnosed the condition of the gearbox 110 and the condition of the rail.

[0050] Fig. Figure 2 is a schematic cross-sectional view showing an axle assembly according to an embodiment of the present invention.

[0051] As in Fig. As shown in Figure 2, the axle assembly 100 includes an axle 102. The axle 102 is connected to a power source (e.g., the traction motor, etc.) and rotates when it receives power from the power source.

[0052] The gearbox 110 can be arranged between the power source and the shaft 102. The gearbox 110 comprises a plurality of gears that mesh with one another to change the rotational speed of the power source and to transmit the changed speed of the power to the shaft 102. A gearbox sensor module 112 is attached to the gearbox 110, and the gearbox sensor module 112 is configured to detect accelerations, rotational speeds, and / or temperatures of the multiple gears.

[0053] The control server 200 can diagnose the condition of the gearbox 110 based on the physical quantity of the gearbox 110 detected by the gearbox sensor module 112.

[0054] The wheels 104 are fixed to both sides of the axle 102. The wheel 104 can be attached to the axle 102 by various methods such as pressing, welding, gearing, etc. Each wheel 104 can be rotatably mounted on the rail. When the axle 102 rotates due to the force of the power source, the wheel 104 rotates on the rail. As a result, the rail vehicle 1 can move.

[0055] Bearings 120 are mounted at both ends of the axle 102. Each bearing 120 rotatably supports the axle 102 against the vehicle body. The bearing 120 comprises an inner ring, an outer ring, and a plurality of rolling elements. The inner ring is fixed to the axle 102 and rotates with the axle. The outer ring surrounds the inner ring outside a radius of the inner ring and is fixed to the vehicle body. The plurality of rolling elements is rotatably arranged between the inner and outer rings. The plurality of rolling elements allows the inner ring to rotate relative to the outer ring.

[0056] The cover assemblies 130 are attached to both ends of the axle 102. The cover assembly 130 primarily prevents the ingress of foreign objects such as water or dust into the bearing 120.

[0057] Fig. Figure 3 is a schematic view showing some components of the axle assembly according to an embodiment of the present invention.

[0058] As in Fig. Figure 3 shows that, according to an embodiment of the present invention, the axle assembly 100 further comprises a housing 140 that surrounds the axle 102. The housing 140 can be separate from and connected to the vehicle body or formed integrally with the vehicle body. As described above, the bearing 120 is arranged between the housing 140 and the axle 102. The inner ring of the bearing 120 is attached to the axle 102 by various methods such as pressing, welding, etc., the outer ring of the bearing 120 is attached to the vehicle body or the housing 140 by various methods such as pressing, welding, etc., and a plurality of rolling elements is arranged between the inner ring and the outer ring.

[0059] The axle assembly 100 comprises the cover assembly 130, which is mounted between the housing 140 or the vehicle body and the axle 102. The cover assembly 130 allows the axle 102 to rotate relative to the housing 140 or the vehicle body. The cover assembly 130 is connected to one end of the housing 140 to prevent foreign matter such as dust or moisture from entering the housing 140. The cover assembly 130 can be detachably attached to the housing 140.

[0060] The cover assembly 130 can be connected to the axis 102 via an extension section 132. The extension section 132 is functionally connected to the axis 102 and extends in an axial direction. Accordingly, the cover assembly 130 comprises a part that is connected to and rotatable with the axis 102, and a part that is connected to and fixed within the housing 140. The cover assembly 130, as a fixed part, also includes a bearing cover 150. The bearing cover 150 is connected directly or indirectly to the housing 140 and has a space in which parts can be formed.

[0061] The cover assembly 130 can also include an axis sensor unit 160 arranged inside the bearing cover 150 and a wireless antenna 162 attached to the bearing cover 150.

[0062] Fig. Figure 4 is a schematic view showing some components of the axle assembly according to another embodiment of the present invention.

[0063] As in Fig. As shown in Figure 4, an axle assembly 130' according to another embodiment of the present invention further comprises a bottom rotor 172 and a bottom cover 170.

[0064] The ground rotor 172 is connected to one end of the extension section 132 and is rotatable together with the extension section 132.

[0065] One end of the bottom rotor 172 is positioned inside the bottom cover 170 by penetrating the bearing cover 150.

[0066] The ground rotor 172 is guided to the ground cover 170 by a brush installed in it.

[0067] The bottom cover 170 is mounted on a surface of the bearing cover 150, the housing or a separate structure connected to the housing 140 or the bearing cover 150.

[0068] The rail vehicle 1 forms an electrical circuit with a pantograph as the positive (+) pole and a rail as the negative (-) pole. Since the bearing 120 is located between the vehicle body, which is electrically connected to the pantograph, and the wheel 104, which is electrically connected to the rail, the pantograph, the vehicle body, the rail, the wheel 104, the axle 102, and the bearing 120 form a closed circuit. However, when high-voltage current flows through the bearing 120, the contact area between the inner ring, the outer ring, and the rolling element is small, so that sparks may occur or electrical erosion may occur at a contact point.

[0069] To prevent this, the current from the floor rotor 172, which rotates through the brush together with the axle 102, should be directed to the floor cover 170.

[0070] Fig. Figure 5 is a schematic cross-sectional view illustrating a configuration of a cover assembly according to an embodiment of the present invention, and Fig. Figure 6 is a schematic top view of a cover assembly according to an embodiment of the present invention.

[0071] As in the Fig. 5 and Fig. As shown in Figure 6, the cover assembly 130 according to an embodiment of the present invention comprises an axle sensor unit 160 and a generator 180 within the bearing cover 150.

[0072] The generator 180 comprises a rotor 182 and a stator 184. The rotor 182 is attached to the extension section 132 of the shaft 102 and can be rotated together with the shaft 102. The stator 184 surrounds the rotor 182 outside of a radial direction, while maintaining a distance from the rotor 182 in the radial direction. Thus, the stator 184 and the rotor 182 are radially opposed. Both the rotor 182 and the stator 184 are wound with coils, and when a magnetic field is generated by applying current to the coil of the stator 184, the current is induced in the coil of the rotor 184, which rotates in the magnetic field. In one embodiment, it is described that the rotor 184 is attached to the extension section 182, but the present description is not limited to this. Depending on the size of the bearing cover 150 and the generating capacity, the rotor 184 can also be attached to the axis 102.The phrase “attached to the axis 102” in this description and the claims is to be understood as encompassing both “attached directly to the axis 102” and “attached to the extension section 132 connected to the axis 102”.

[0073] In some embodiments, an encoder 183 can be mounted on an outer circumferential surface of the rotor 182 and an encoder sensor 185 on the stator 184. In the encoder 183, an N-pole and an S-pole are arranged alternately in the circumferential direction, and the encoder sensor 185 faces the encoder 183 with an intervening air gap to detect a change in the magnetic field that occurs when the encoder 183 rotates. As a result, the encoder sensor 185 can detect the rotational speed of the encoder 183, i.e., the rotational speed of the shaft 102.

[0074] At least one printed circuit board (PCB) is attached to an outer circumference of the stator 184. The PCB 186 is electrically connected to the stator 184 and the rotor 182. Consequently, the PCB 186 can provide an input (e.g., current) to the stator 184 and receive an output (e.g., current) from the rotor 182. Furthermore, the PCB 186 is electrically connected to the encoder sensor 185 to receive a signal corresponding to the rotational speed of the axis 102 as detected by the encoder sensor 185.

[0075] An axis sensor unit 160 with an accelerometer 192 and a temperature sensor 194 is mounted on the circuit board 186. The accelerometer 192 can be a 3-axis accelerometer capable of measuring the accelerations of axis 102 or axis assembly 100 in the x, y, and z directions.

[0076] The temperature sensor 194 can measure the temperature of the axis 102 or the axis assembly 100.

[0077] The axis sensor unit 160 also includes a power control system 197, a battery 198 and a wireless communication unit 199, which is mounted on the circuit board 186.

[0078] The power control system 197 can control the power supplied to the stator 184 and the power of the rotor 182. That is, the power control system 197 can control the current applied to the stator 184 and receive current from the rotor 182 to charge the battery 198. Furthermore, the power control system 197 supplies power to the battery 198 and also powers the encoder sensor 185, the accelerometer 192, and the temperature sensor 194, enabling the sensors 185, 192, and 194 to detect the physical parameters of the axle assembly 100.

[0079] In addition, the power control system 197 supplies the wireless communication unit 199 with power from the battery 198 to enable wireless communication with the control server 200 or the peripheral axis assembly 100.

[0080] Battery 198 can be charged with the current generated by generator 180 and supply power to the individual components of the axle sensor unit 160 according to the control by the power control system 197. Battery 198 can be a secondary battery that can be charged and discharged.

[0081] The wireless communication unit 199 converts the physical quantities detected by the encoder sensor 185, the accelerometer 192, and the temperature sensor 194 into signals suitable for wireless communication and transmits these converted signals wirelessly to the control server 200 or the peripheral axis assembly 100 via wireless communication protocols such as Bluetooth, Zigbee, WiFi, LTE, etc. The signal converted by the wireless communication unit 199 is transmitted to the control server 200 or the peripheral axis assembly 100 via a wireless antenna 162. The signal can also be received by the peripheral axis assembly 100, the control server 200, or a gear sensor module 112 via the wireless antenna 162.

[0082] A wired connector 163 can additionally be installed in the bearing cover 150. The wired connector 163 is electrically connected to the components on the circuit board 186 to supply external power and transmit / receive data, or it is wired to the gear sensor module 112, which is contained in the axle assembly 100, to supply power to the gear sensor module 112 or to transmit / receive the signal to the gear sensor module 112.

[0083] According to an embodiment of the present invention, the generator 180, which can be mounted in the bearing cover 150, can generate a power output of approximately 10 W or more, taking into account the dimensions of the bearing cover 150 and the average rotational speed of the axis 102. At a power output of 10 W, the 3-axis acceleration (or vibration) (75,000 data points) of the axis assembly 100, the temperature (one data point) of the axis assembly 100, and the rotational speed (one data point) of the axis 102 are measured at a sampling rate of 25 kHz or more per second in order to transmit 75,002 data points via wireless communication.In order to perform the frequency analysis using the vibration of the axle assembly 100, the data should be sampled at a sampling rate of at least 10 kHz or more, preferably 12.5 kHz, and according to an embodiment of the present invention, since data sampling and wireless communication at a sampling rate of 25 kHz or more are made possible by using a capacitor of the generator 180, which can be mounted in the bearing cover 150, sufficient data for the frequency analysis can be obtained.

[0084] Furthermore, according to an exemplary embodiment of the present invention, the generator 180 and the axle sensor units 160, including the sensors 185, 192, and 194, are all arranged in the bearing cover 150, and the extension section 132 connected to the rotor 182 of the generator 180 projects to the outside of the bearing cover 150. Accordingly, the cover assembly 130, according to an exemplary embodiment of the present invention, can be installed in the axle 102 when the bearing cover 150 is connected to the housing 140 and the extension section 132 is connected to the axle 102. Thus, the cover assembly 130, according to an exemplary embodiment of the present invention, can be used without any special modification of the existing axle assembly of the rail vehicle.

[0085] Furthermore, the data acquired by one axis assembly 100 can be transmitted wirelessly to the other axis assembly 100 located near the control server 200. In such an arrangement, the axis assembly 100 closest to the control server 200 can transmit all data for each axis assembly 100 to the control server 200 wirelessly. Consequently, the power consumption for wireless communication can be reduced, and the capacity of the generator 180 can be decreased.

[0086] Since the data is transmitted via the wireless communication setup, a wiring harness may be useful.

[0087] Fig. 7 is a schematic top view of a cover assembly according to another embodiment of the present invention, and Fig. Figure 8 shows part of a cross-section along line AA of Fig. 7.

[0088] As in the Fig. 7 and Fig. As shown in Figure 8, the cover assembly 130 according to another embodiment of the present invention can comprise a generator 180 and an axle sensor unit 160, and the axle sensor unit 160 can be attached to a stator 184 of the generator 180 via a holder 300.

[0089] In one example, the holder 300 can have a ring-shaped form that surrounds the generator 180. In this case, the holder 300 can be mounted on the stator 184. In the other example, the holder 300 can have a ring-shaped form that surrounds the shaft 102 and can be located on one side of the generator 180. In this case, the holder 300 can be attached to one side of the stator 184.

[0090] The holder 300 comprises a first and a second holder 302 and 304, which are detachably connected to each other.

[0091] The first holder 302, which has the shape of an annular disc, comprises an outer and an inner circumferential surface.

[0092] Since the outer diameter of the first holder 302 is smaller than the inner diameter of the housing 140, the axle sensor unit 160 can be mounted in the housing 140, and if the inner diameter of the first holder 302 is larger than the outer diameter of the generator 180 or the axle 102, the first holder 302 can surround the generator 180 or the axle 102.

[0093] The first holder 302 has first and second projections 314 and 316, which are spaced apart from each other in the radial direction, and each of the first and second projections 314 and 316 projects axially to one side. A printed circuit board 186 is located between the first and second projections 314 and 316.

[0094] The second holder 304 has the shape of an annular disc and a size corresponding to the first and second projections 314 and 316. After the circuit board 186 is positioned between the first and second projections 314 and 316, the second holder 304 is connected to the first and second projections 314 and 316 to secure the circuit board 186 to the holder 300.

[0095] The holder 300 can be electrically connected to the generator 180 and the axis sensor unit 160. For example, the holder 300 can include a first connector electrically connected to the generator 180, a second connector electrically connected to the circuit board 186, and an internal wire electrically connecting the first and second connectors. Accordingly, when the circuit board 186 is mounted on the holder 300, a connector pin of the circuit board 186 can be connected to the second connector of the holder 300, thus establishing an electrical connection between the holder 300 and the circuit board 186.When the holder 300, equipped with the circuit board 186, is mounted on the outer circumference of the generator 180, the connector pin of the generator 180 can be connected to the first connector of the holder 300, thereby establishing the electrical connection between the circuit board 186 and the generator 180.

[0096] Alternatively, the generator 180 and the axle sensor unit 160 can be connected wirelessly.

[0097] The holder 300 protects the axis sensor unit 160, including the circuit board 186, from external influences. This means that the circuit board 186, in the form of a thin plate, is mounted on the generator 180 by the holder 300 to protect both the circuit board 186 and the axis sensor unit 160 mounted on it from external influences. The holder 300 can also incorporate a protective layer 310 applied to the circuit board 186 for further protection. After the circuit board 186 is mounted on the holder 300, the protective layer 310 on the circuit board 186 can be formed from silicone or epoxy.

[0098] In one example, before mounting the circuit board 186 on the holder 300, the protective layer 310 can be formed on the holder 300 by silicone or epoxy, and the circuit board 186 can also be mounted on it.

[0099] In one example, the first holder 302 and the second holder 304 can be screwed together. For this purpose, the screw holes 306 and 308 can be positioned at locations corresponding to the first and second projections 314 and 316, respectively, and to the second holder 304. This description illustrates, by way of example, that the first and second holders 302 and 304 are screw-coupled, but the coupling of the first and second holders 302 and 304 is not limited to this. Various coupling arrangements can be used that are capable of detachably connecting the first and second holders 302 and 304. The first and second holders 302 and 304 are detachably connected so that, in the event of a defect in the axle sensor unit 160, it can be easily replaced.

[0100] To further facilitate the replacement of faulty components of the axis sensor unit 160, the circuit board 186 can be divided into two or more functional modules and mounted on the holder 300, as shown in Fig. 9 and Fig. 10 shown.

[0101] Fig. 9 is a schematic top view of a cover assembly according to a further embodiment of the present invention, and Fig. Figure 10 shows part of a cross-section along line BB of Fig. 9.

[0102] As in Fig. As shown in Figure 9, the circuit board 186 can be divided into four functional modules, e.g. a wireless communication module 186a, a power module 186b, an operating module 186c and a sensor module 186d.

[0103] The wireless communication module 186a can include a wireless communication unit 199 and a supporting circuit for this; the power module 186b can include a power control system 197, a battery 198 and a supporting circuit for this; the operating module 186c can include a supporting circuit for the wireless communication module 186a, the power module 186b and the sensor module 186d; and the sensor module 186d can include an encoder sensor 185, an accelerometer 192, a temperature sensor 194 and a supporting circuit for this.

[0104] As in Fig. As shown in Figure 10, the holder 300 further comprises at least two spokes 313 which connect the first and second projections 314 and 316 and divide the respective functional modules 186a, 186b, 186c and 186d and form spaces to which the respective functional modules 186a, 186b, 186c and 186d can be attached in order to easily separate the respective functional modules 186a, 186b, 186c and 186d from the holder 300.

[0105] In Fig. Figure 9 shows four functional modules 186a, 186b, 186c and 186d and four spokes 313, but the number of functional modules and the number of spokes are not limited to four. For example, if there are two functional modules, the number of spokes 313 can be two.

[0106] Furthermore, a filler dam 312 can be arranged between the protective layer 310 and the holder 300 (e.g., a periphery of the second holder 304 and the spoke 313) to allow each of the functional modules 186a, 186b, 186c, and 186d to be easily separated from the holder 300. The filler dam 312 connects the protective layer 310 and the holder 300, so that the protective layer 310 (which is attached to each functional module) can be easily detached from the holder 300. When the second holder 304 is separated from the first holder 302, the protective layer 310 and the individual functional modules 186a, 186b, 186c, and 186d are attached to the second holder 304. When the filler dam 312, which surrounds the protective layer 310 to which the functional module to be replaced is attached, is removed from the second holder 304, the function to be replaced and the protective layer 310 attached to the functional module can be separated from the second holder 304.A new functional module is then placed on the first holder 302, and the second holder 304 is connected to the first holder 302. Next, the filler dam 312 is attached to the periphery of the second holder 300 and the spoke 313, and the protective layer 310 is formed on the functional module to replace it. This allows for easy replacement of the functional module. Furthermore, since only the faulty functional module needs to be replaced, maintenance costs can be reduced.

[0107] As already mentioned, the holder 300 can include an electrical connecting element for electrically connecting the individual functional modules 186a, 186b, 186c and 186d of the circuit board 186 and the generator 180. In one example, the electrical connecting element can be a connector and the connector pin.

[0108] The following refers to the Fig. 11 and Fig. 12 a mounting method of the axle assembly 100 according to an embodiment of the present invention is described.

[0109] Fig. Figure 11 is a cross-sectional view showing some components of an axle assembly according to an embodiment of the present invention, and Fig. Figure 12 is a cross-sectional view showing some components of an axle assembly according to another embodiment of the present invention.

[0110] The in Fig. The axle assembly 100 shown in Figure 11 further comprises an axle housing 320, a vehicle speed sensor 330, a connecting adapter 340 and a speed sensor housing 350.

[0111] First, the extension section 132 is connected to the axle 102. That is, the extension section 132 is arranged at one end of the axle 102, and the axle 102 and the extension section 132 are coupled by a coupling means such as a bolt 134, etc. A keyway 135 may be formed at a specific location on the extension section 132.

[0112] The generator 180 and the axle sensor unit 160, which are connected to each other via the holder 300, are then coupled to the axle housing 320. The generator 180 and the axle sensor unit 160 are arranged in the bearing cover 150, and the bearing cover 150 is connected to the holder 300. The axle housing 320 has a substantially cylindrical shape, and the generator 180 and the axle sensor unit 160 are mounted on an inner circumferential surface of the axle housing 320. The connecting adapter 340 serves to connect the holder 300, which connects the generator 180 and the axle sensor unit 160 to the axle housing 320. For this purpose, the connecting adapter 340 comprises a cylindrical part 342 and a disc part 344. The cylindrical section 342 can be coupled to the inner circumferential surface of the axle housing 320 by means of coupling means such as the bolt 346, etc., and the disc part 344 can be coupled to the holder 300 by means of coupling means 346, etc.The axle sensor unit 160 is coupled to the generator 180 via the holder 300, and the disc part 344 of the connecting adapter 340 is coupled to the holder 300. Subsequently, the cylindrical part 342 of the connecting adapter 340 is connected to the inner circumferential surface of the axle housing 320.

[0113] After the generator 180 and the axle sensor unit 160 are coupled to the axle housing 320, the axle housing 320 is mounted on the inner circumferential surface of the housing 140. The axle housing 320 can be pressed onto the housing 140 or connected to the housing 140 by a coupling means, such as a bolt. When the axle housing 320 is pressed onto the housing 140, the generator 180 is functionally connected to the extension section 132. For this purpose, the keyway 136 is formed on the inner circumferential surface of the rotor 182 of the generator 180, and the keyway 136 of the rotor 182 is key-coupled with the keyway 135 of the extension section 132. Consequently, when the axle 102 and / or the extension section 132 rotates, the rotor 182 also rotates. Furthermore, the bearing cover 150 forms a predetermined gap to the outer circumferential surface of an end section of the extension section 132.One end of the extension section 132 penetrates the bearing cover 150 without rotating with the bearing cover 150.

[0114] A speed plate 330 is then attached to one end of the extension section 132. Speed ​​teeth 332 are formed at regular intervals on the outer circumferential surface of the speed plate 330, and these speed teeth 332 can generate a current change proportional to the rotational speed in a speed sensor (not shown). The speed plate 330 is arranged without interfering with the rotation of the bearing cover 150 and is coupled to the extension section 132 by coupling means such as the bolt 334, etc.

[0115] Accordingly, the speed plate 330 is rotatable together with the extension section 132.

[0116] Finally, a speed sensor housing 350 is attached to one end of the axle housing 320.

[0117] The in Fig. The axle assembly 100 shown in Figure 12 also includes the axle housing 320, the bottom rotor 172 and the connecting adapter 340.

[0118] First, the extension section 132 is connected to the axle 102. That is, the extension section 132 is arranged at one end of the axle 102, and the axle 102 and the extension section 132 are coupled by a coupling means such as a bolt 134, etc. A keyway 135 may be formed at a specific location on the extension section 132.

[0119] The generator 180 and the axle sensor unit 160, which are connected to each other via the holder 300, are coupled to the axle housing 320. The axle housing 320 has a substantially cylindrical shape, and the generator 180 and the axle sensor unit 160 are mounted on an inner circumferential surface of the axle housing 320. The connecting adapter 340 serves to connect the holder 300, which connects the generator 180 and the axle sensor unit 160 to the axle housing 320. For this purpose, the connecting adapter 340 comprises a cylindrical part 342 and a disc part 344. The cylindrical section 342 can be coupled to the inner circumferential surface of the axle housing 320 by means of coupling means such as the bolt 346, etc., and the disc part 344 can be coupled to the holder 300 by means of coupling means 346, etc.Consequently, the axle sensor unit 160 is coupled to the generator 180 via the holder 300, and the disc part 344 of the connecting adapter 340 is coupled to the holder 300. Subsequently, the cylindrical part 342 of the connecting adapter 340 is connected to the inner circumferential surface of the axle housing 320.

[0120] After the generator 180 and the axle sensor unit 160 are coupled to the axle housing 320, the axle housing 320 is mounted on the inner circumferential surface of the housing 130. The axle housing 320 can be pressed onto the housing 140 or connected to the housing 140 by a coupling means, such as a bolt. When the axle housing 320 is pressed onto the housing 140, the generator 180 is functionally connected to the extension section 132. For this purpose, the keyway 136 is formed on the inner circumferential surface of the rotor 182 of the generator 180, and the keyway 136 of the rotor 182 is key-coupled with the keyway 135 of the extension section 132.

[0121] When the axis 102 and / or the extension section 132 rotates, the rotor 182 also rotates.

[0122] Furthermore, the bearing cover 150 forms a predetermined gap to the outer circumferential surface of an end section of the extension section 132. One end of the extension section 132 penetrates the bearing cover 150 without rotating with the bearing cover 150.

[0123] The ground rotor 172 is guided to the axle housing 320 via the brush installed therein. The ground rotor 172 is attached to the extension section 132 by a coupling means such as a bolt 174, etc. Accordingly, the ground rotor 172 is rotatable together with the extension section 132.

[0124] Finally, the bottom cover 170 is mounted at one end of the axle housing 320.

[0125] Although this invention has been described in connection with embodiments currently considered practical, the invention is not limited to the disclosed embodiments. Rather, it is intended to cover various modifications and equivalent arrangements that fall within the spirit and scope of the appended claims.

Claims

[1] Cover assembly installed in an axle assembly comprising an axle rotating by means of a force transmitted from a force source, a housing surrounding an end section of the axle, and a bearing arranged between the end section of the axle and the housing to rotatably support the axle on the housing, the cover assembly comprising: a storage cover with a space inside; a generator comprising a rotor that is functionally connected to the axis and rotates together with the axis, and a stator that surrounds the rotor in a radial direction while maintaining a predetermined distance from the rotor in the radial direction; a printed circuit board (PCB) that is electrically connected to the generator, provides an input to the stator and receives an output from the rotor; at least one sensor mounted on the circuit board that detects at least one physical parameter of the axle assembly; and a wireless antenna attached to the bearing cover and capable of wirelessly transmitting data corresponding to at least one physical quantity detected by the at least one sensor, wherein the generator, the circuit board and at least one sensor are arranged in a space formed by a bearing cover. [2] The cover assembly according to claim 1, wherein: an encoder that rotates with the rotor, mounted on the rotor and an encoder sensor, which detects the rotation of the encoder, is mounted on the stator. [3] The cover assembly according to claim 1, wherein: the at least one sensor comprises an acceleration sensor that measures the acceleration of the axle assembly and a temperature sensor that measures the temperature of the axle assembly. [4] The cover assembly according to claim 1, further comprising: a power control system mounted on the circuit board that controls the input applied to the stator and the rotor output; a battery mounted on the circuit board that absorbs the rotor's power and is charged by the power control system; and a wireless communication module that is mounted on the circuit board and enables data exchange through wireless communication. [5] The cover assembly according to claim 1, further comprising: a floor cover attached to one side of the bearing cover; and a ground rotor connected to one end of the axle and rotating together with the axle, and which protrudes into the ground cover by penetrating the bearing cover. [6] The cover assembly according to claim 1, wherein: the rotor and stator are configured to generate a power output of 10 W or more. [7] The cover assembly according to claim 1, wherein: which at least one sensor is configured to detect at least one physical quantity of the axis assembly with a sampling rate of 10 kHz or more. [8] The cover assembly according to claim 1, further comprising: a holder that is mounted on the stator and electrically connects the circuit board to the generator, with the circuit board being mounted on the holder. [9] The cover assembly according to claim 8, wherein: the holder comprises a first and a second holder, which are detachably connected to each other, and The circuit board is positioned between the first and second holders and is attached to the holder by coupling the first and second holders. [10] The cover assembly according to claim 9, wherein: the first holder has a first and a second projection which are spaced apart from each other in the radial direction and each project to one side in the axial direction, the circuit board is positioned between the first and second protrusions, and the second holder is coupled to the first and second projections. [11] The cover assembly according to claim 8, wherein: The circuit board is detachably attached to the holder. [12] The cover assembly according to claim 8, further comprising: a protective layer applied to the circuit board. [13] The cover assembly according to claim 12, wherein: The circuit board is divided into two or more functional modules and is detachably attached to the holder. [14] The cover assembly according to claim 10, wherein: the holder also has at least two spokes connecting the first and second projections, and the circuit board is divided into two or more functional modules and is removablely mounted on a space formed by the first and second projections and spokes. [15] The cover assembly according to claim 14, further comprising: a protective layer applied to the circuit board, wherein a filling dam is arranged between the protective layer and a periphery and a spoke of the second holder. [16] An axle assembly comprising: a cover assembly according to claim 1; a holder that is mounted on a stator and electrically connects a circuit board to the generator; an extension section that is functionally connected to an end section of an axis and extends in an axial direction; a bearing cover connected to the holder, in which the generator and the circuit board are arranged; an axle housing that is attached to an inner circumferential surface of an end section of a housing; and a connecting adapter for mounting the holder to the axle housing, the circuit board is mounted on the holder, and The extension section and a rotor of the generator are coupled via a keyway. [17] The axle assembly according to claim 16, wherein: one end of the extension section penetrates a bearing cover without interfering with the bearing cover, and The axle assembly also includes: a speed plate attached to one end of the extension section and a speed sensor housing attached to one end of the axle housing. [18] The axle assembly according to claim 16, wherein: one end of the extension section penetrates a bearing cover without interfering with the bearing cover, and The axle assembly also includes: a ground rotor attached to one end of the extension section, and a bottom cover that is attached to one end of the axle housing. [19] The axle assembly according to claim 16, further comprising: a gearbox that changes the rotational speed of the power from a power source via a multitude of gears and transmits the power, whose rotational speed is changed, to the shaft; a gear sensor module configured to detect at least one of the following quantities: accelerations, rotational speeds, and temperatures of the multitude of gears; and a wired connector that is mounted on the bearing cover and connected to the circuit board to ensure power supply. [20] The axle assembly according to claim 19, wherein: A measured value from the transmission sensor module is transmitted wirelessly via the wireless antenna or via the wired connector to the circuit board.

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